EKKO EK20R, EK20RL User Manual

EK20R(EK20RL) Electric Counterbalanced Forklift

Manual

Note Please read this manual before using!

Note Please do not use it before completing the installation!

Aug.2018

Introduction

In order to meet the needs of the national environmental protection request, To reduce industrial pollution and improve productivity, we design and produce new series of EK20R(EK20RL) type Counterbalanced forklift on the basis of absorption of the advantages of domestic & overseas Electric forklift ,they are especially suitable for cargo loading and unloading, handling, stacking, etc for food, bank, light textile, station, port, logistics and other enterprises. And it can apply widely if inter-grate with different fixture

The Electric forklift adopt wild-field lifting system ,EPS system , new AC controller and Open type lamp holder .It is equipped high-quality Motors, Battery, and high-power pumping stations .Therefor it is Convenient operation .With Good view, Flexible steering ,Reliable braking ,Good power, Low noise, No pollution and Attractive appearance .

This manual describes the technical parameters of the Counterbalanced Electric Forklift , working principle and operation, maintenance, and other aspects. It can help operators use the Counterbalanced Electric Forklift more reasonable, make its maximum effect.

It is hoped that Operator strictly abide the regulations and the precautions in this manual when using the machine. Carefully use them so that your Forklift can be in the best working condition for long period of time to maximize its effectiveness. And create better economic benefits.

The Statement

Our company production model EK20R(EK20RL) type Counterbalanced Electric Forklift is a special motor vehicle used in Factory ,Tourist attractions ,Amusement places which is specified by “special equipment safety supervision regulations”

Contents

1.General Introduction ............................................................................................ 1

2.Proper usage ............................................................................................................ 2

3..Introduction of the product ............................................................................... 4

3.1Model overview ............................................................................................................ 4

3.2Product Schematic diagram&Parameter ............................................................ 4

4.The Schematic diagram of Operating Mechanism ...................................... 5

5.Structure ,Principle and Adjustment of main parts of forklift ............... 7

5.1Drive system .................................................................................................................. 8

5.2Steering system ............................................................................................................ 9

5.3 Brake structure &Brake Schematic .................................................................... 12

5.4 Operating system ...................................................................................................... 21

5.5 Electric system ........................................................................................................... 22

5.6 Hyraulic system ......................................................................................................... 24

6.Electrical Schematic diagram .......................................................................... 25

7.Hydraulic Schematic diagram ......................................................................... 26

8.Operating Specification ..................................................................................... 27

8.1 Sart ,Running and Parking .................................................................................. 27

8.2 Steering wheel angle front and rear adjustment .......................................... 28

8.3 Pedal accelerator operation .................................................................................. 28

8.4 Pedal brake operation ............................................................................................. 28

8.5Use of emergency power off safety switch ...................................................... 28

8.6 Use of Horn and Reversing horn ......................................................................... 28

8.7 Hydraulic joystick operation ................................................................................ 29

8.8 Battery display ........................................................................................................... 29

8.9 Handling & Stacking operation ............................................................................ 29

9.Maintain Introduction ....................................................................................... 30

9.1 Repair & Maintenance Safety procedure ......................................................... 30

9.2 Routine Maintenance .............................................................................................. 31

9.3 Professional Maintenance manual ..................................................................... 31

9.4 Maintenance ,Recharging and replacement of the Accumulator ........... 34

10.Safety Operation And Cautions .................................................................... 42

10.1General Rul ................................................................................................................ 42

10.2 Transportation & Storage ................................................................................... 42

10.3 Check before using................................................................................................. 43

10.4Safety Operation Rules .......................................................................................... 43

11.Toubleshooting .................................................................................................. 46

11.1Hand and foot brake common faults and troubleshooting ................... 46

11.2Steering system common faults and troubleshooting ............................ 47

11.3Lifting system common faults and troubleshooting 48

11.4Electric system common faults and troubleshooting ............................. 49

11.5Gearbox failure reasons and troubleshooting.............................................. 50

11.6Multi-way valve failure reasons and troubleshooting ............................ 50

11.7Gear pump failure reasons and troubleshooting ........................................ 52

11.8Other common faults and troubleshooting ................................................... 54

12.Aftersales ............................................................................................................. 55

1、General Introduction

EK20R(EK20RL) type 4 wheel Counterbalanced Electric Forklift adapts battery as the power source ,uses the AC motor as the power to drive the device through the gear transmission. The lifting and tilting of the fork are driven by the DC motor and Hydraulic drive to push the cylinder to lift the cargo. Because the device is using Power to travelling & lift ,Forward & back tilting and side shift. therefor it is Low effort, High efficiency, Stable cargo operation. Simple operation, Safe and reliable .Low noise & No pollution

The biggest advantage for 4wheel counterbalanced electric forklift is that it is adopt optimized design ,wide-view mast, the mast and rubber tube pulley block are more compact .It is not easy to block the operator’s sight. The size of the fork frame is increased, and the field of view is wide .Large arc roof guard ,The best angle of the grid to increase the driver’s upper view .The right-hand control handle fully reflects ergonomics ,Improves the comfort of handling and reduces the labor intensity of the operator .

The device is suitable for Stacking & Handling cargo on firm ,flat floors

The service environment：

a. Altitude does not exceed 1200m；

b. Indoor room temperature at +5℃ to +40℃ ；

c. When environment temperature at +40℃,the relative humidity can’t over 50%,at low temperature ,allow bigger relative humidity

d. Firm, Flat ground 。

e. It is forbidden to use this car in corrosive environment such as flammable and explosive or acid base.

2、Proper use

Please using the Counterbalanced electric forklift according to this specification.

The Forklift described in this manual is a self-controlled series of Counterbalanced Electric forklift. With Multi-way valve control forklift lifting ,forward backward tilting ,side shifting etc function.

Improper use can cause personal injury or machine damage. Operators or operating companies need to ensure proper using, make sure that the truck is operated only by personnel who are trained and authorized to use the truck.

The Truck needs to be used on a firm ,flat ,intact surface and suitable surface ,the truck is designed for indoor use at room temperature from+5°C to +40°C

Use under light load without using permanent barriers or pits ,It is forbidden to operate on the slope .During Operation ,The goods must be placed approximately at the center of the truck’s load center

Lifting or Carrying people is strictly prohibited ,if carried goods .The goods must fall on the lifting point 。

It is prohibited to use this truck on lifting or loading ramps。

The rated capacity is marked on the capacity label or nameplate. And the operator must pay attention to the warming signs and safety instructions

Operating lighting must be at lest 50LUX

Modification

Any modification that may affect the truck rated capacity, stability, or safety operations must be approved in advance by the Truck’s original manufacturer or Its authorized Manufacturer or its successor. This includes the effects of changes such as Braking ,steering ,Visibility, and the addition of removable accessories.

After the manufacturer or its successor approves the modification or change ,The capacity name plate ,Label, identification marks, operation and maintenance manual must be changed accordingly

Truck damage caused by not following Instruction will lose its

warranty

3、Introduction of the product

3.1Model overview

This manual is a collection of EA type 1.6T counterbalanced Electric forklift

(Hereinafter referred to as Forklift )

3.2Product Schematic diagram & Parameter

Model

EK20RL

EK20R

Power

Electric

Operator type

Rider

Load capacity

Q (lbs)

4500

Lift height

h3 (in)

189

216

Load center

c (in)

Distance between fork

x(in)

18.8

Wheel base

y (in)

55.5

Service weight(include

(lbs)

7500

8000

Tires

solid tire

Front

6.5-10-10P

6.5-10-10PR

Rear

5.0-8-14PR

Wheel number，Front/Rear

2×/2

Front wheel base

b10 (in)

Rear wheel base

b11 (in)

36.2

Mast tilt Forward/backward

a/b (°)

3/6

Lowered mast height

h1 (in)

Free lift height

h2 (in)

Extended mast height

h4 (in)

221

249

Over guard height

h6 (in)

86.5

Seat height

h7 (in)

Towing pin height

h10 (in)

Overall length

l1 (in)

129

Body length

l2 (in)

85.4

Overall width

b1/ b2 (in)

Fork size

s/e/l (in)

1.4/3.94/4

1.4/3.94/45.2

Width of fork

b3 (in)

36.2

Floor clearance under mast

m1 (in)

4.5

Ground clearance ,centre of

m2 (in)

4.9

Aisle width for pallets

Ast (in)

165

Aisle width for pallets

Ast (in)

169

Turning radius

Wa (in)

84.6

Travel speed,

(M/h)

7.5/9

Lifting speed Laden/unladen

(in/s)

9.9/16

Lowering speed

(in/s)

9.5/10.2

Max gradient performance

(%)

12/15

Service brake

Hydraulic

Driving motor

(kW)

7.5

Lifting Motor

(kW)

7.7

Battery, According to DIN

Battery Voltage/Capacity

(V/Ah)

48/420

Battery weight（±5%）

(lbs)

1500

Battery size

(in)

30/25.6/19

30/25.6/19.6

Type of drive unit

Sound pressure level at the

(dB(A))

Steering type

Hydraulic

4、The Schematic diagram of Operating Mechanism

The Forklift uses battery as power source ,uses electric and hydraulic to travelling ,& Lifting, Forward & backward tilting and steering Operating Mechanism diagram:

1. Hand braking 2.Combination switch 3.Steering wheel

4.Lifting handle 5.tilting handle 6.Side shift handle 7.Accelerator 8.Foot brake

9.Emergency stop switch

5、Structure ,Principle and Adjustment of main parts of

forklift

5.1Drive system

5.1.1Overview

The forklift is powered by batter and use a frequency conversion system to convert direct current into Alternating current by controlling the AC motor on the driving wheel . The AC motor converts the high speed and low torque to the low speed and high torque through the gear reducer ,And the driving wheel performs the action. The travel speed is controlled by frequency conversion motor speed .which is controlled by accelerator

5.1.2Reducer casing

The reducer casing is located between the transaxle and the traveling motor. The two pairs of cylindrical helical gears reduce the rotational speed from the output shaft of the traveling motor and increase the torque transmitted from the transmission shaft .and then transmit this torque to the differential.。

Reducer casing

1. Reducer casing body 2.Washer 3. Spring washer 4.Bolt

5.Bolt 6.Hexagon nut 7.Flat washer 8. Spring washer 9.Washer 10.bolt 11. Flat washer

12.Spline housing 13.Adjust gasket unit 14.Sign of mechanical transmission 15. Bolt 16.Spiral bevel gear

17.Round nut 18.Tab Washer for Round nut

2. 19. Spring washer 20.Gasket unit 21. Gasket unit 22.

Bearing seat 23.Bearing 24.Bushing 25.Oil seal

26.Bearing 27.Bearing cover 28.Head bolt 29. Spring washer 30. O-Ring 31.Pad

5.2Steering system

5.2.1Overview

Steering system is composed of steering wheel .Steering shaft ,Steering gear, Steering pump0 and steering axle .The steering shaft is connected to the steering gear through the universal joint, And the connecting shaft is connected to the steering wheel through the universal joint ,The steering Column can be tilted back and forth to an appropriate position. And the steering axle is mounted on the tailstock at the rear of frame .And there is a steering on the left and the right respectively .The steering cylinder is pushed by the steering cylinder piston rod through the connecting rod to deflect the steering wheel to realize steering .

Steering device

5.2.2Steering axle

Steering axle is a box-shaped cross-section welded structure composed of steering axle body ,steering cylinder ,connecting rod,steering joint and steering wheel.The steering trapezoid adopts a crank slider mechanism and the cylinder

piston rod pushes the steering joint through the connecting rod to deflect the steering wheel .then realizing steering . The steering axle is fixed to the tailstock at the rear of the frame by the front and rear pins through the fixing plate ,That is, the vibration damping pad ,So that the axle body can swing around the pin shaft .There is on joint on the left and right sides of the steering axle .and two tapered rollers on the rear hub. The bearing is mounted on the joint shaft .The wheel is fixed to the hub by the rim .And the inside bearing is provided with an oil seal to keep grease in the hub .and the steering joint cavity

1.Bolt M16×12 2.Spring washer 6 3.tighten pin

4.Connecting rod

5.Joint bearing 6.Bushing 7.Left joint

8.Steering axle body

9.Steering cylinder 10.cotter 5×50 11.Groove nut

12.Flat whasher27

13.Adjust Washer 14.Bearing 15.Pin roll

16.Flat whashe12

17.Spring washe12 18.BoltM12×40 19. Nut M10×1.25

20.Bolt M10×1.25×40 21.Bent neck grease nipple M6 22.Oil seal

23.Bearing

24. O-ring 25.8×1.8 25.Steering joint kingpin 26.steering joint adjust washer 27.Bearing 28.set pin 29.Right joint 30.Washer 8 31.O-Ring32. Nut M8×1.25

33.Framework oil seal 34.Steering hub 35.Bearing 36Bolt M8×18 37.Flat whasher24 38. Nut M24×2

39.Cotter 5×45 40.Wheel hub cover

5.2.3 Adjustment ,Maintenance essential

(1) As the picture shows, Grease the inner cavity of the hub, the inner and outer bearings and the hub cap, and also apply some grease to the lip of the oil seal.

(2) Fixing the outer ring of the bearing to the hub and attaching the hub to

the steering joint shaft .

(3)Install the flat washer and tighten the castle nut with a torque of 206-235n.m(21-24kgm),loosen the slotted nut and then screw the nut back, the torque is 9.8n.m(1kgm)

(4) Gently tap the hub with a wooden hammer and turn the hub 3-4 turns to

ensure that the hub is not loose.

(5)Tighten the Castle nut so that the slot is aligned with the opening pin hole on the Knuckle

(6) Then Tap the hub with a wooden hammer and turn hub 3-4 turns by hands to ensure smooth rotation and measure the torque of the hub, the value is

2.94-7.8N.m(0.3-0.8kgm)

(7) When the turning torque is higher than the specified value ,It can be retracted 1/6 turn, and then measure its rotational torque

(8) When reach the specified torque .Then lock the slot nut with a split pin .

Preload adjustment

5.2.4 Check after reinstallation of steering system

(1) Turn the steering wheel from side to side and see whether the forces are

even, and the rotation is steady .

(2)Check weather the oil pressure pipe is arranged correctly, and weather the left and right steering is installed in reverse .

(3) Lift the rear wheel .slowly turn the steering wheel left and right .and repeat it several times to remove the air from the hydraulic lines and cylinders .

5.3 Braking system and schematic diagram.

5.3.1overview

The brake mode of the forklift consists of two type: service brake and parking brake .

The service brake refers to the braking method used by the forklift during the operation, Brake with foot brakes

When the brake cylinder pumps the brake drum to the same force as the

main brake shoe and the auxiliary brake shoe until the upper end of the brake

Inject grease

shoe is pressed against the fixed pin ,the brake shoe moves in the direction of the brake drum. After the fixed pin is pressed ,the frictional force between the friction lining and the brake drum is increased. Because the main brake shoe gives the auxiliary brake shoe a much greater pressure than the brake cylinder pressure ,thereby generating a large braking force .

The parking brake is mainly used in the parking state to prevent accidents caused by slopes. A parking switch is mounted on the parking brake .and the control circuit is disconnected in the parking The stop brake must be released before the forklift starts to walk ,and the control circuit can be connected .Parking brake has the function of adjusting tightness .

5.3.2Brake pedal

The brake pedal portion is constructed as shown in the figure ,and the pedal converts in the pedaling force acting on the pedal into the brake oil pressure by the push rod of the master cylinder .

1．Brake oil cup 2.Brake pedal 3.Brake master Cylinder 4.brake support 5.limit bolt 6.brake sensor

5.3.3 Brake master cylinder

The master cylinder includes a valve seat ,a check valve, a return spring ,and a main cup, piston and auxiliary cup. The master cylinder piston is actuated by the operating brake pedal through the push rod, when the brake pedal is depressed ,the push rod pushes the piston forward .and the brake fluid in the pump body flows back to the oil storage tank through the oil return port until the main the cup stops the oil return hole .After the main cup is pushed over the oil return port .The brake fluid in the front chamber of the main pump is compressed and the check valve is opened to flow through the brake line to the sub -Pump.in this way ,each of the sub-pump pistons protrudes outward ,so that the brake shoe friction plate and the brake drum are in the contact with each other to achieve the effect of deceleration of braking .At this time ,The rear chamber of the piston is replenished by the brake fluid from the oil return port and the oil inlet port .When the brake pedal is released ,the piston is pressed back by the return spring and the brake fluid in each brake cylinder is also compressed by the brake shoe return spring .so that the brake fluid returns to the original position. The brake fluid in the master cylinder flows back to the oil storage tank through the oil return port .The pressure of the check valve is adjusted to a certain ratio with the residual pressure in the brake line and the

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EKKO EK20R, EK20RL User Manual

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